An in vitro evaluation of marginal fit zirconia crowns fabricated by a CAD-CAM dental laboratory and a milling center

The Effect of a Digital Manufacturing Technique, Preparation Taper, and Finish Line Design on the Marginal Fit of Temporary Molar Crowns: An In-Vitro Study

The aim of this study is to investigate the combined effect of a digital manufacturing technique (subtractive vs. additive), preparation taper (10° vs. 20° TOC), and finish line (chamfer vs. shoulder) on the marginal adaptation of temporary crowns following cementation with a compatible temporary cement. Four mandibular first molar typodont teeth were prepared for full coverage crowns with standard 4 mm preparation height as follows: 10° TOC with the chamfer finish line, 10° TOC with the shoulder finish line, 20° TOC with the chamfer finish line and 20° TOC with the shoulder finish line. Each of the four preparation designs were subdivided into two subgroups to receive CAD/CAM milled and 3D-printed crowns (n = 10). A total of 80 temporary crowns (40 CAD/CAM milled and 40 3D-printed) were cemented to their respective die using clear temporary recement in the standard cementation technique. The samples were examined under a stereomicroscope at ×100 magnification following calibration. Linear measurements were performed at seven equidistant points on each axial surface and five equidistant points on each proximal surface. One-way ANOVA analysis and Tukey HSD (Honestly Significance Difference) were performed. The best marginal fit was seen in group 8, while the poorest fit was noted in group 2. Shoulder finish lines and 10° TOC resulted in higher marginal gaps, especially in CAD/CAM milled group. The selection of 3D-printed crowns may provide a better marginal fit within the range of clinical acceptability. Marginal gaps were within clinical acceptability (50 and 120 µm) in all groups except group 2.

Clinical evaluation of 3D-printed zirconia crowns fabricated by selective laser melting (SLM) for posterior teeth restorations: Short-term pilot study

Background/purpose

Zirconia crowns (ZrC) without veneering porcelain have become an effective alternative in clinical practice. Monolithic zirconia restorations fabricated by the dry milling method do not have acceptable clinical properties. This study evaluated the periodontal qualities of three-dimensional printed ZrC using the modified United States Public Health Service (USPHS) criteria.

Materials and methods

A total of 15 patients who required dental crowns were recruited, and all 15 teeth were restored with digital 3D-printed ZrC. All crowns were assessed at the time of crown placement and 2, 6, and 24 weeks post-placement. Clinical parameters, including plaque index, gingival index, probing depth, crown marginal integrity, and attrition of the antagonist's teeth, were evaluated and recorded.

Results

According to the Modified California Dental Association quality evaluation system, 100% of the crowns received satisfactory grades. Despite the significant increase in plaque index and gingival index at two weeks post-ZrC placement, there was no deterioration in probing depth. Moreover, there was discard usage of ZrC on the antagonist's teeth at 24 weeks posttreatment. Of the 15 crowns, one tooth had to be extracted due to a vertical root fracture. Overall, the digital 3D-printed crowns showed no adverse effects on periodontal tissues after 24 weeks of follow-up.

Conclusion

The 3D-printed ZrC showed no periodontal problems. It can serve as an alternative for patients, particularly those with high esthetic expectations.

Prospective Clinical Evaluation of Posterior Third-Generation Monolithic Zirconia Crowns Fabricated with Complete Digital Workflow: Two-Year Follow-Up

Clinical studies on the behavior of posterior translucent monolithic zirconia restorations are lacking. We assessed the clinical outcome and survival rate of posterior third-generation monolithic zirconia crowns over a 2-year period. A total of 24 patients, requiring 30 posterior full-contour restorations were selected. All abutments were scanned, and crowns were milled and cemented with a self-adhesive dual cure cement. Crowns were assessed using the California Dental Association’s criteria. Gingival status was assessed by evaluating the gingival index, plaque index, periodontal probing depth of the abutments and control teeth, and the margin index of the abutment teeth. Statistical analyses were performed using the Friedman and the Wilcoxon signed-rank tests. During the 2-year follow-up, no biological or mechanical complications were observed, and the survival and success rate was 100%. All restorations ranked as satisfactory throughout the follow-up period. The gingival index and plaque index were worse at the end of the 2-year follow-up. The margin index was stable during the 2 years of clinical service. No significant differences were recorded in periodontal parameters between crowns and control teeth. Third-generation monolithic zirconia could be a reliable alternative to posterior metal–ceramic and second-generation monolithic zirconia posterior crowns.

In-situ SEM cyclic nanoindentation of pre-sintered and sintered zirconia materials

Efficient diamond machining of zirconia requires a comprehensive understanding of repetitive diamond indentation mechanics. This paper reports on in-situ cyclic nanoindentations of pre-sintered and sintered zirconia materials performed inside a scanning electron microscope (SEM). In-situ SEM imaging of cyclic indentation processes and high-magnification SEM mapping of indentation imprints were conducted. The elastic and plastic behaviors of pre-sintered and sintered zirconia materials were investigated as a function of the cyclic nanoindentation number using the Sakai and Sakai-Nowak models. For pre-sintered zirconia, cyclic nanoindentation induced quasi-plastic deformation, causing localized agglomeration of zirconia crystals with microcracks and large cracking along the indentation edge. Severely compressed, fragmented, and pulverized zirconia crystals and smeared surfaces were also observed. For sintered zirconia, shear bands dominated quasi-plastic deformation with the formation of edge pile-ups and localized microfractures occurred at indentation apex and diagonals. All elastic and plastic behaviors for pre-sintered and sintered zirconia materials revealed significantly microstructure-dependent. Pre-sintered zirconia yielded significantly lower contact hardness, Young's moduli, resistance to plasticity, elastic deformation components, and resistance to machining-induced cracking, and higher elastic and plastic displacements than sintered state. Meanwhile, all the behaviors for the two materials were independent from the cyclic nanoindentation number. A model was proposed for cyclic nanoindentation mechanics, revealing their cyclic indentation-induced microstructural changes in the two zirconia materials. This study advances the fundamental understanding of nanoindentation mechanics of zirconia materials.

Evaluation of Marginal/Internal Fit and Fracture Load of Monolithic Zirconia and Zirconia Lithium Silicate (ZLS) CAD/CAM Crown Systems

Fit accuracy and fracture strength of milled monolithic zirconia (Zi) and zirconia-reinforced lithium silicate (ZLS) crowns are important parameters determining the success of these restorations. This study aimed to evaluate and compare the marginal and internal fit of monolithic Zi and ZLS crowns, along with the fracture load, with and without mechanical aging. Thirty-two stone dies acquired from a customized master metal molar die were scanned, and ceramic crowns (16 Zi Ceramill Zolid HT⁺ and 16 ZLS Vita Suprinity) were designed and milled. Absolute marginal discrepancies (AMD), marginal gaps (MG), and internal gaps (IG) of the crowns, in relation to the master metal die, were evaluated using x-ray nanotomography (n = 16). Next, thirty-two metal dies were fabricated based on the master metal die, and crowns (16 Zi; 16 ZLS) cemented and divided into four groups of eight each; eight Zi with mechanical aging (MA), eight Zi without mechanical aging (WMA), eight ZLS (MA), and eight ZLS (WMA). Two groups of crowns (Zi-MA; ZLS-MA) were subjected to 500,000 mechanical cycles (200 ± 50 N, 10 Hz) followed by axial compressive strength testing of all crowns, until failure, and the values were recorded. Independent sample t tests (α = 0.05) revealed no significant differences between Zi and ZLS crowns (p > 0.05); for both internal and marginal gaps, however, there were significant differences in AMD (p < 0.005). Independent samples Mann–Whitney U and Kruskal–Wallis tests revealed significant differences between the two materials, Zi and ZLS, regardless of fatigue loading, and for the individual material groups based on aging (α = 0.05). Multiple comparisons using Bonferroni post-hoc analysis showed significant differences between Zi and ZLS material groups, with or without aging. Within the limitations of this study, the ZLS crown fit was found to be on par with Zi, except for the AMD parameter. As regards fracture resistance, both materials survived the normal range of masticatory forces, but the Zi crowns demonstrated greater resistance to fracture. The monolithic Zi and ZLS crowns seem suitable for clinical application, based on the fit and fracture strength values obtained.

Fracture Load of CAD/CAM Fabricated Cantilever Implant-Supported Zirconia Framework: An In Vitro Study

The fracture resistance of computer-aided designing and computer-aided manufacturing CAD/CAM fabricated implant-supported cantilever zirconia frameworks (ISCZFs) is affected by the size/dimension and the micro cracks produced from diamond burs during the milling process. The present in vitro study investigated the fracture load for different cross-sectional dimensions of connector sites of implant-supported cantilever zirconia frameworks (ISCZFs) with different cantilever lengths (load point). A total of 48 ISCZFs (Cercon, Degudent; Dentsply, Deutschland, Germany) were fabricated by CAD/CAM and divided into four groups based on cantilever length and reinforcement of distal-abutment: Group A: 9 mm cantilever; Group B: 9 mm cantilever with reinforced distal-abutment; Group C: 12 mm cantilever; Group D: 12 mm cantilever with reinforced distal-abutment (n = 12). The ISCZFs were loaded using a universal testing machine for recording the fracture load. Descriptive statistics, ANOVA, and Tukey's test were used for the statistical analysis (p < 0.05). Significant variations were found between the fracture loads of the four ISCZFs (p = 0.000); Group-C and B were found with the weakest and the strongest distal cantilever frameworks with fracture load of 670.39 ± 130.96 N and 1137.86 ± 127.85 N, respectively. The mean difference of the fracture load between groups A (810.49 + 137.579 N) and B (1137.86 ± 127.85 N) and between C (670.39 ± 130.96 N) and D (914.58 + 149.635 N) was statistically significant (p = 0.000). Significant variations in the fracture load between the ISCZFs with different cantilever lengths and thicknesses of the distal abutments were found. Increasing the thickness of the distal abutment only by 0.5 mm reinforces the distal abutments by significantly increasing the fracture load of the ISCZFs. Therefore, an increase in the thickness of the distal abutments is recommended in patients seeking implant-supported distal cantilever fixed prostheses.

Marginal and internal fit of full ceramic crowns milled using CADCAM systems on cadaver full arch scans

Background

Chairside systems are becoming more popular for fabricating full-ceramic single restorations, but there is very little knowledge about the effect of the entire workflow process on restoration fit. Therefore, this study aimed to compare the absolute marginal discrepancy (AMD) and the full internal fit (FULL) of all-ceramic crowns made by two chairside systems, Planmeca FIT and CEREC, with detailed and standard mill settings.

Methods

One upper molar was prepared for an all-ceramic crown in human cadaver maxilla. Full-arch scans were made by Emerald or Omnicam four times each. Twenty-four e.max crowns were designed and milled by the Planmill 30s or 40s or CEREC MCXL mills with either detailed or standard settings. The cadaver tooth was extracted, and each crown was fixed on it and scanned by a high-resolution microCT scanner. The AMD and FULL were measured digitally in mesio-distal and bucco-lingual 2D slices. The actual and predicted times of the milling were also registered.

Results

No differences were observed between detailed or standard settings in either system. The AMD was significantly higher with CEREC (132 ± 12 μm) than with either Planmill 30s (71 ± 6.9 μm) or 40s (78 ± 7.7 μm). In standard mode, the FULL was significantly higher with CEREC (224 ± 9.6 μm) than with either Planmill 30s (169 ± 8.1 μm) or 40s (178 ± 8.5 μm). There was no difference between actual and predicted time with the two Planmeca models, but with CEREC, the actual time was significantly higher than the predicted time. The 30s had significantly higher actual and predicted times compared to all other models. Across all models, the average milling time was 7.2 min less in standard mode than in detailed mode.

Conclusions

All fit parameters were in an acceptable range. No differences in fit between Planmeca models suggest no effect of spindle number on accuracy. The detailed setting has no improvement in the marginal or internal fit of the restoration, yet it increases milling time.

An Experimental Strategy for Capturing the Margins of Prepared Single Teeth with an Intraoral Scanner: A Prospective Clinical Study on 30 Patients

Purpose: To present an experimental strategy for successfully capturing the margins of prepared single teeth with an intraoral scanner (IOS). Methods: The protocol was as follows: (1) an intraoral impression was captured with an IOS, without taking care of the visibility of the margins; (2) a partial analog impression was taken by means of a 3D-printed custom tray filled with polyvinylsiloxane light, after the removal of a retraction cord; (3) the hollow portion of the analog impression, with the preparation margins clearly visible, was scanned extraorally with the same IOS; (4) the scan of the analog impression was imported into computer-assisted-design (CAD) software, where its normals were inverted; (5) the scan with inverted normals was registered on the first intraoral scan, and replaced it; (6) the technician designed the final restoration, which was fabricated and delivered for application. The study outcomes were: (1) the marginal adaptation of the final crown; (2) the quality of interproximal contacts; and (3) the quality of occlusal contacts. Results: Thirty patients (18 males, 12 females; mean age 51.3 ± 11.6 years) were selected for this study. All these patients were restored with a monolithic translucent zirconia crown, fabricated following the aforementioned protocol. The clinical precision and the marginal adaptation of the crowns were optimal, interproximal contact points were perfect, and the only necessary adaptations were occlusal, with some minor precontacts that had to be polished. Conclusions: The present protocol seems to be compatible with the fabrication of clinically precise zirconia crowns. Further studies are needed to confirm these results.

Marginal fit of full contour monolithic zirconia in different thicknesses and layered zirconia crowns

Aim:

Use of monolithic zirconia for fabrication of all-ceramic crowns eliminates several shortcomings of layered zirconia crowns. Long-term success of restorations highly depends on the marginal fit. The crown thickness is among the factors that affect the marginal integrity. Meanwhile, reduced thickness of crowns has several advantages such as preservation of tooth structure. The aim of this study was to evaluate the marginal fit of monolithic zirconia crowns in reduced thickness and to compare the marginal fit of full-contour monolithic zirconia in different thicknesses with layered zirconia crowns.

Materials and Methods:

In this in vitro study, two standard brass dies (7 mm × 5 mm length diameter) were prepared with a heavy chamfer finish line with 0.5 and 1 mm depth. By using a CAD-CAM system, 30 crowns were made in three groups (n = 10) of 1-mm thick layered zirconia, 1-mm thick monolithic zirconia, and 0.5-mm thick monolithic zirconia. Crowns were placed on master dies and randomly numbered. The marginal gap was measured on 18 points by using a digital microscope (×230). The mean ± standard deviation (SD) values were calculated and analyzed by Statistical Package for the Social Sciences (SPSS) software program through Kruskal–Wallis and Mann–Whitney tests (α = 0.05).

Results:

The marginal gap of 1-mm layered zirconia was significantly different from that of 1-mm monolithic zirconia (P = 0.001) and 0.5-mm monolithic zirconia (P = 0.004). Analysis of variance (ANOVA) revealed no significant difference between 0.5 and 1 mm thicknesses of monolithic zirconia (P = 0.141).

Conclusion:

Marginal gap in all the three groups was clinically acceptable. The two different thicknesses of monolithic zirconia crowns had no significant effect on the restoration marginal fit; however, layered zirconia crowns showed a significantly higher marginal gap than monolithic zirconia crowns.

Zirconia crowns cemented on titanium bars using CAD/CAM: a five-year follow-up prospective clinical study of 9 patients

BACKGROUND

The purpose of this prospective clinical study was to evaluate clinical results of the passive fit of the substructure in the Toronto bridge and the chipping or delamination of the ceramic veneering on the zirconia-support, after 5 years, in nine patients rehabilitated with zirconia crowns cemented on titanium bars using CAD/CAM technology.

METHODS

A total of nine healthy patient fully edentulous in the upper and lower jaws with non-contributory past medical anamnesis needing full fixed total prosthesis maxilla and mandible were included in this clinical study, where a total 9 mandibles and 9 jaws were treated. The inclusion criteria in order for a patient to participate in the study were: a signed consent form, fully edentulous in the upper and lower jaws, required a full fixed total prosthesis restoration. The exclusion criteria were age limitation of less than 18 years old, chemotherapy, head and neck radiation therapy, diabetes or periodontal disease, smoking and severe illness. All patients received zirconia crowns cemented on titanium bars using CAD/CAM technology. The primary outcome of this study was to examine the survival rate of the zirconia crowns cemented on titanium bars using CAD/CAM technology during the observation period. Any chipping or delamination of the zirconia crowns of the restorations was considered as failure. The secondary outcome was to evaluate the passive fit of the substructure on the implants, loose of occlusal screws, implant survival and satisfactory occlusion.

RESULTS

In 5 years of follow-up no evidence of chipping or delamination of the ceramic veneering on the zirconia crown supported were observed. Fifteen finished protesis (93.75%) showed satisfactory occlusion and only one case (6.25%) required significant occlusal adjustment. During the first year recall all bars were stable (100%) no mobility of protheses was recorded. After 5 years all bars were stable (100%) and no mobility of protheses was recorded.

CONCLUSION

The computerized workflow for the process of building bar and prosthesis ensures reproducible results and excellent adaptation and passive insertion of them, as well as conditions for avoiding mechanical complications and guarantees stability of screw-implant abutments.